Hydrant nozzle cap

ABSTRACT

A nozzle cap for a fire hydrant includes a cap cover comprising a metal material; and a cap body defining a cap axis, the cap body comprising: an inner housing comprising a metal material; and an outer housing comprising a non-metal material, the outer housing disposed axially between the inner housing and the cap cover, the outer housing comprising a substantially circumferential wall, the substantially circumferential wall defining a cavity between the inner housing and the cap cover, wherein a first end of the substantially circumferential wall engages the inner housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.17/245,419, filed Apr. 30, 2021, which is a continuation of U.S.application Ser. No. 16/428,744, filed May 31, 2019, which issued asU.S. Pat. No. 11,473,993 on Oct. 18, 2022, each of which is herebyspecifically incorporated by reference herein in its entirety.

TECHNICAL FIELD

This disclosure relates to fire hydrants. More specifically, thisdisclosure relates to a hydrant nozzle cap for detecting leaks in afluid system connected to a fire hydrant.

BACKGROUND

Fire hydrants are commonly connected to fluid systems, such as municipalwater infrastructure systems and water mains, through stand pipes.Because these fluid systems are typically partially or entirely locatedunderground, it can be difficult to detect leaks within the fluidsystems. Additionally, it can be difficult to access these fluid systemsfor monitoring. Fire hydrants can provide convenient above-ground accessto the fluid systems. Leaks within the fluid systems can send vibrationsthrough the fluid system and up the stand pipes to the fire hydrants.These vibrations propagating through the stand pipes and fire hydrantscan be monitored to detect leaks within the connected fluid system.However, fire hydrants can be subjected to other sources of vibrationsuch as wind, rain, ambient noise from loud passing vehicles, or directcontact such as pedestrians bumping into fire hydrants or bicyclistsleaning their bicycles against fire hydrants. These sources ofbackground noise can trigger false alarms or make it more difficult fora potential leak to be detected.

Leak detection systems can be provided for detecting leaks in the fluidsystems and can be attached to a nozzle of the fire hydrant. Often, thesensitive electronic components of the leak detection system are housedin an enclosed cavity. Pressure changes within the cavity can createstresses on structural components of the leak detection system, whichcan lead to damage or failure of the structural components.Additionally, moisture and other undesirable elements can enter a cavitythat is not adequately sealed, and can damage the electronic components.To protect the electronic components, they often must be potted withinthe cavity. Furthermore, producing such leak detection systems can beexpensive and time consuming. Customers who may not desire a leakdetection system often need to seek out alternative solutions forcapping the nozzle because of the added cost of the leak detectionsystem. Also, customers who may desire to replace an ordinary nozzle capwith a nozzle cap comprising a leak detection system must purchase anentirely new and expensive nozzle cap.

SUMMARY

It is to be understood that this summary is not an extensive overview ofthe disclosure. This summary is exemplary and not restrictive, and it isintended to neither identify key or critical elements of the disclosurenor delineate the scope thereof. The sole purpose of this summary is toexplain and exemplify certain concepts of the disclosure as anintroduction to the following complete and extensive detaileddescription.

Disclosed is a nozzle cap for a fire hydrant comprising a cap body, thecap body comprising an inner housing and an outer housing, the outerhousing defining a cavity; a vibration sensor received within the cavityand configured to detect leaks in a fluid system connected to the firehydrant; and a metal insert contacting the vibration sensor and theinner housing.

Also disclosed is a nozzle cap for a fire hydrant comprising a cap covercomprising a metal material; a cap body comprising: an inner housingcomprising a metal material; and an outer housing comprising a non-metalmaterial, the outer housing received between the inner housing and thecap cover, the outer housing defining a cavity; and a vibration sensorreceived within the cavity and configured to detect leaks in a fluidsystem connected to the fire hydrant.

A modular nozzle cap for a fire hydrant is also disclosed, the modularnozzle cap comprising a cap cover; a cap body comprising: an innerhousing configured to engage the fire hydrant; and an outer moduleremovably received between the inner housing and the cap cover; and afastener for removably coupling the outer module to the cap cover andthe inner housing. Disclosed is a nozzle cap for a fire hydrantcomprising an outer housing defining a first end, a second end oppositethe first end, and a substantially circumferential wall extending fromthe first end to the second end; an antenna coupled to the substantiallycircumferential wall of the outer housing; a cap cover coupled to theouter housing at the first end; and an inner housing coupled to theouter housing at the second end.

Also disclosed is a nozzle cap for a fire hydrant comprising a cap bodydefining a first end, a second end opposite the first end, a wallextending from the first end, and threading defined proximate to thesecond end, the threading configured to couple the cap body to the firehydrant; and an antenna adhered to the wall of the cap body; and a capcover coupled the cap body at the first end.

A method of detecting a leak in a fluid system is disclosed, the methodcomprising providing a nozzle cap comprising a substantiallycircumferential wall, an antenna attached to the substantiallycircumferential wall, and a sensor in communication with the antenna;mounting the nozzle cap to a nozzle of a fire hydrant, the fire hydrantconnected to a fluid system; detecting an anomaly in the fluid systemwith the sensor, the anomaly resulting from a leak in the fluid system;and transmitting a signal with the antenna, the signal indicative of theleak in the fluid system.

Additionally, disclosed is a nozzle cap for a fire hydrant comprising acap cover comprising a metal material; and a cap body defining a capaxis, the cap body comprising: an inner housing comprising a metalmaterial; and an outer housing comprising a non-metal material, theouter housing disposed axially between the inner housing and the capcover, the outer housing comprising a substantially circumferentialwall, the substantially circumferential wall defining a cavity betweenthe inner housing and the cap cover, wherein a first end of thesubstantially circumferential wall engages the inner housing.

Also disclosed is a nozzle cap for a fire hydrant comprising: a capcover comprising a metal material; a cap body defining a cap axis, thecap body comprising: an inner housing comprising a metal material; andan outer housing comprising a non-metal material, the outer housingdisposed axially between the inner housing and the cap cover, the outerhousing comprising a substantially circumferential wall, thesubstantially circumferential wall defining a substantially cylindricalsurface; and an antenna assembly comprising at least an antenna and anadhesive, the antenna assembly a free first side end, a free second sideend, a free upper end, and a free lower end, the adhesive adhering theantenna directly to a first portion of the substantially cylindricalsurface, wherein a second portion of the substantially cylindricalsurface is uncovered by the antenna assembly, wherein an area of thesecond portion is greater than an area of the first portion.

Various implementations described in the present disclosure may includeadditional systems, methods, features, and advantages, which may notnecessarily be expressly disclosed herein but will be apparent to one ofordinary skill in the art upon examination of the following detaileddescription and accompanying drawings. It is intended that all suchsystems, methods, features, and advantages be included within thepresent disclosure and protected by the accompanying claims. Thefeatures and advantages of such implementations may be realized andobtained by means of the systems, methods, features particularly pointedout in the appended claims. These and other features will become morefully apparent from the following description and appended claims, ormay be learned by the practice of such exemplary implementations as setforth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and components of the following figures are illustrated toemphasize the general principles of the present disclosure. The drawingsare not necessarily drawn to scale. Corresponding features andcomponents throughout the figures may be designated by matchingreference characters for the sake of consistency and clarity.

FIG. 1 is a perspective view of a hydrant assembly comprising a nozzlecap connected to a nozzle of a fire hydrant, in accordance with oneaspect of the present disclosure.

FIG. 2 is a perspective rear view of the nozzle cap of FIG. 1 .

FIG. 3A is an exploded view of the nozzle cap of FIG. 1 .

FIG. 3B is a cross-sectional detail view of the assembled nozzle cap ofFIG. 1 , taken along line 3-3 in FIG. 3A.

FIG. 4 is a top perspective view of an outer housing of the nozzle capof FIG. 1 , according to another aspect of the present disclosure,illustrating a vibration sensor thereof.

FIG. 5A is a top perspective view of a metal insert of the nozzle cap ofFIG. 1 .

FIG. 5B is a bottom perspective view of the outer housing of FIG. 4 ,comprising the metal insert of FIG. 5A.

FIG. 5C is a cross-sectional detail view of the outer housing of FIG. 4, taken along line 5-5 in FIG. 3A.

FIG. 6 is an exploded view of the outer housing of FIG. 4 and a housinglid therefor, according to another aspect of the present disclosure.

FIG. 7A is a cross-sectional detail view of the outer housing of FIG. 4and the housing lid of FIG. 6 , taken along line 7-7 in FIG. 6 .

FIG. 7B is a cross-sectional detail view of the outer housing of FIG. 4and the housing lid of FIG. 6 , taken along line 7-7 in FIG. 6 , whereinthe outer housing is ultrasonically welded to the housing lid.

FIG. 8 illustrates an exploded view of the nozzle cap according toanother aspect of the present disclosure.

FIG. 9 illustrates an exploded view of the nozzle cap and the nozzle,according to another aspect of the present disclosure.

FIG. 10 illustrates a cross-sectional view of the nozzle cap of FIG. 9mounted to the nozzle of FIG. 9 , taken along line 10-10 in FIG. 9 .

FIG. 11 illustrates an exploded view of the nozzle cap and the nozzle,according to another aspect of the present disclosure.

FIG. 12 illustrates a cross-sectional view of the nozzle cap of FIG. 11mounted to the nozzle of FIG. 11 , taken along line 12-12 of FIG. 11 .

FIG. 13 illustrates an exploded view of the outer housing and thehousing lid, according to another aspect of the present disclosure.

FIG. 14 illustrates a cross-sectional detail view of the nozzle cap ofFIG. 1 taken along line 14-14 in FIG. 3 .

DETAILED DESCRIPTION

The present disclosure can be understood more readily by reference tothe following detailed description, examples, drawings, and claims, andthe previous and following description. However, before the presentdevices, systems, and/or methods are disclosed and described, it is tobe understood that this disclosure is not limited to the specificdevices, systems, and/or methods disclosed unless otherwise specified,and, as such, can, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularaspects only and is not intended to be limiting.

The following description is provided as an enabling teaching of thepresent devices, systems, and/or methods in its best, currently knownaspect. To this end, those skilled in the relevant art will recognizeand appreciate that many changes can be made to the various aspects ofthe present devices, systems, and/or methods described herein, whilestill obtaining the beneficial results of the present disclosure. Itwill also be apparent that some of the desired benefits of the presentdisclosure can be obtained by selecting some of the features of thepresent disclosure without utilizing other features. Accordingly, thosewho work in the art will recognize that many modifications andadaptations to the present disclosure are possible and can even bedesirable in certain circumstances and are a part of the presentdisclosure. Thus, the following description is provided as illustrativeof the principles of the present disclosure and not in limitationthereof.

As used throughout, the singular forms “a,” “an” and “the” includeplural referents unless the context clearly dictates otherwise. Thus,for example, reference to “an element” can include two or more suchelements unless the context indicates otherwise.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

For purposes of the current disclosure, a material property or dimensionmeasuring about X or substantially X on a particular measurement scalemeasures within a range between X plus an industry-standard uppertolerance for the specified measurement and X minus an industry-standardlower tolerance for the specified measurement. Because tolerances canvary between different materials, processes and between differentmodels, the tolerance for a particular measurement of a particularcomponent can fall within a range of tolerances.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event or circumstance can or cannot occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

The word “or” as used herein means any one member of a particular listand also includes any combination of members of that list. Further, oneshould note that conditional language, such as, among others, “can,”“could,” “might,” or “may,” unless specifically stated otherwise, orotherwise understood within the context as used, is generally intendedto convey that certain aspects include, while other aspects do notinclude, certain features, elements and/or steps. Thus, such conditionallanguage is not generally intended to imply that features, elementsand/or steps are in any way required for one or more particular aspectsor that one or more particular aspects necessarily include logic fordeciding, with or without user input or prompting, whether thesefeatures, elements and/or steps are included or are to be performed inany particular aspect.

Disclosed are components that can be used to perform the disclosedmethods and systems. These and other components are disclosed herein,and it is understood that when combinations, subsets, interactions,groups, etc. of these components are disclosed that while specificreference of each various individual and collective combinations andpermutation of these may not be explicitly disclosed, each isspecifically contemplated and described herein, for all methods andsystems. This applies to all aspects of this application including, butnot limited to, steps in disclosed methods. Thus, if there are a varietyof additional steps that can be performed it is understood that each ofthese additional steps can be performed with any specific aspect orcombination of aspects of the disclosed methods.

Disclosed is a hydrant assembly and associated methods, systems,devices, and various apparatus. The hydrant assembly can comprise a firehydrant and a vibration sensor. It would be understood by one of skillin the art that the disclosed hydrant assembly is described in but a fewexemplary aspects among many. No particular terminology or descriptionshould be considered limiting on the disclosure or the scope of anyclaims issuing therefrom.

FIG. 1 is a perspective view of a hydrant assembly 100 comprising a firehydrant 110 and a vibration sensor 380 (shown in FIG. 3A) in accordancewith one aspect of the present disclosure. The fire hydrant 110 cancomprise a barrel 120, a nozzle cap 150, and a bonnet 180. The barrel120 can define a top barrel end 122 and a bottom barrel end 124 disposedopposite from the top barrel end 122. The barrel 120 can besubstantially tubular, and the barrel 120 can define a barrel axis 101extending from the top barrel end 122 to the bottom barrel end 124. Inthe present aspect, the barrel axis 101 can be substantially verticallyaligned wherein the barrel axis 101 is aligned with the force ofgravity.

The barrel 120 can comprise a top flange 126 disposed at the top barrelend 122 and a base flange 128 disposed at the bottom barrel end 124. Thebase flange 128 can be fastened to a stand pipe flange 199 of a standpipe 198 of a fluid system (not shown), such as a water main for exampleand without limitation. Example aspects of the stand pipe 198 can beformed from a metal material, such as, for example, iron or steel. Thebase flange 128 can be fastened to the stand pipe flange 199 by aplurality of fasteners 130. A bonnet flange 182 of the bonnet 180 can beattached to the top flange 126 of the barrel 120, such as with aplurality of fasteners (not shown) similar to the fasteners 130. Thebonnet 180 can comprise an operation nut 184, or “op nut”, which can berotated to open and close a main valve (not shown) positioned at thebottom barrel end 124 or below in the stand pipe 198 in order torespectively supply or cut off pressurized water flow to the firehydrant 110.

The barrel 120 can define one or more nozzles 140 a,b. The nozzle cap150 can be screwed onto the nozzle 140 a to seal the nozzle 140 a. Withthe nozzle cap 150 sealing the nozzle 140 a, pressurized water cannotescape through the nozzle 140 a when the main valve (not shown) is in anopen position. The nozzle cap 150 can define a cap nut 152 which can beturned, such as with a wrench, to tighten or loosen the nozzle cap 150on the nozzle 140 a. In example aspects, the fire hydrant 110 can beformed from a metal material, such as iron, and as such, the nozzle 140can be formed from a metal material. In some aspects, the nozzle 140 acan be a Storz nozzle, as described in further detail below.

FIG. 2 is a perspective rear view of the nozzle cap 150 of the firehydrant 110 of FIG. 1 . The nozzle cap 150 can comprise a cap body 210and a cap cover 280. Example aspects of the cap cover 280 can be formedfrom a metal material, such as for example, ductile iron. The cap body210 can define a first body end 212 and a second body end 214 disposedopposite from the first body end 212. The cap body 210 can furthercomprise an inner housing 230 and an outer module, such as an outerhousing 240. According to example aspects, the inner housing 230 can beformed from a metal material, such as, for example, ductile iron, andthe outer housing 240 can be formed from a plastic material. Exampleaspects of the plastic material of the outer housing 240 can be aglass-filled plastic material to provide an improved acousticperformance. The cap cover 280 can be attached to the first body end 212of the cap body 210 at the outer housing 240. The inner housing 230 ofthe cap body 210 can define a threaded bore 216 extending into the capbody 210 from the second body end 214 to an inner wall 220 of the capbody 210. The threaded bore 216 can define a cap axis 201 of the capbody 210, and the cap axis 201 can extend from the first body end 212 tothe second body end 214. According to example aspects, the nozzle cap150 can be a modular system wherein the outer module, such as the outerhousing 240, can be easily removed and/or replaced, as desired. Forexample, it may be desired to remove the outer housing 240 temporarilyfor repair or to replace the removed outer housing 240 with a new outerhousing 240 or a different outer module. The modularity of the modularnozzle cap 150 is described in further detail below with respect toFIGS. 3A, 6, and 8 .

The threaded bore 216 can define internal threading 218, and thethreaded bore 216 can be screwed onto the nozzle 140 a (shown in FIG. 1), for example, a Storz nozzle, to mount the nozzle cap 150 on thenozzle 140 a by rotating the nozzle cap 150 about the cap axis 201. Inthe present aspect, the internal threading 218 can be straight threadingthat does not taper from the second body end 214 towards the inner wall220. In other aspects, the internal threading 218 can be taperedthreading that tapers from the second body end 214 towards the innerwall 220. A gasket 222 can be positioned adjacent to the inner wall 220,and the gasket 222 can be configured to form a seal with the nozzle 140a (shown in FIG. 1 ) when the nozzle cap 150 is screwed onto the nozzle140 a in a sealed position. As described below with respect to FIGS. 6and 7 , the gasket 222 can be selected based on its thickness, measuredaxially along the cap axis 201, to alter a rotational indexing of thenozzle cap 150 relative to the nozzle 140 a.

FIG. 3A is an exploded view of the nozzle cap 150. As shown, the outerhousing 240 of the cap body 210 can define a cavity 310 extendinginwards into the cap body 210 from the first body end 212 to the innerwall 220. In the present aspect, the cavity 310 can extend axiallyinward relative to the cap axis 201. The inner wall 220 can separate thecavity 310 from the threaded bore 216 (shown in FIG. 2 ). The cap body210 can define a circumferential wall 312 which partially encloses thecavity 310 and extends circumferentially around the cavity 310 relativeto the cap axis 201. A cavity opening 313 to the cavity 310 can bedefined at the first body end 212, and a cavity gasket 314 can extendaround the cavity opening 313. As shown, example aspects of the nozzlecap 150 can further comprise one or more of the antennas 316 installedon the circumferential wall 312 and within the cavity 310, as shown.According to example aspects, the antenna(s) 316 can be attached to thecircumferential wall 312 by a fastener, such as, for example, anadhesive, such as glue, a mechanical fastener, such as a screw or clip,or any other suitable type of fastener known in the art, or combinationthereof. As described above, the outer housing 240 can be formed from aplastic material, or another non-ferrous material, so that the materialof the outer housing 240 does not interfere with the signaling abilityof the antenna 316.

The cavity gasket 314 can be configured to form a watertight seal withthe cap cover 280 to enclose and seal the cavity 310. As such, theelectronic components (e.g., the sensor 380, the antenna 316, a printedcircuit board 362, a battery pack 360) within the cavity 310 can beprotected from undesirable external elements, such as water and dirt.Thus, the watertight seal provided by the cavity gasket 314 caneliminate the need to protect the electronic components through pottingthe electronic components within the cavity 310.

The inner housing 230 can comprise one or more posts 332 configured toengage a gap 522 (shown in FIG. 5B) formed between the circumferentialwall 312 and an internal wall 524 (shown in FIG. 5B) of the outerhousing 240 of the cap body 210. Example aspects of the posts 332 can bemonolithically formed with the inner housing 230 and can be formed fromthe same material thereof, such as a metal material like ductile iron.Each of the posts 332 can define an inner fastener hole 334 configuredto align with outer fastener holes 344 of the outer housing 240 and capfastener holes 384 of the cap cover 280. A fastener, such as a securityscrew 336, can engage each of the aligned sets of fastener holes334,344,384 to couple the inner housing 230, outer housing 240, and capcover 280 together. In example aspects, as shown, the cavity gasket 314can be configured to curve around the outer fastener holes 344, suchthat the cavity gasket 314 does not interfere with the security screws336 engaging the outer fastener holes 344. Furthermore, as describedabove, the nozzle cap 150 can be a modular system, wherein the outerhousing 240 can be easily removed and/or replaced. In the presentaspect, the outer housing 240 can be removed by simply unscrewing thesecurity screws 336 from the fastener holes 334,344,384 to detach theouter housing 240 from the inner housing 230 and the cap cover 280. Ifdesired, a new outer housing 240 or another outer module, such as themechanical spacer 810 shown in FIG. 8 , can replace the removed outerhousing 240.

The nozzle cap 150 can further comprise the battery pack 360 and theprinted circuit board (“PCB”) 362, each disposed within the cavity 310.The PCB 362 can be attached to a mounting bracket 364 which can besecured within the cavity 310 by one or more fasteners (not shown). Thenozzle cap 150 can also comprise the vibration sensor 380, and thevibration sensor 380 can be disposed within the cavity 310. Thevibration sensor 380 can define a sensor axis 301 which can beperpendicular to the cap axis 201. The vibration sensor 380 can beattached to the circumferential wall 312, and the vibration sensor 380can extend generally inward from the circumferential wall 312 and intothe cavity 310.

The battery pack 360, the PCB 362, the vibration sensor 380, and theantenna(s) 316 can be connected together in electrical communication.The vibration sensor 380 can be configured to detect leaks within thefluid system (not shown) by monitoring vibrations travelling up thestand pipe 198 (shown in FIG. 1 ) and through the fire hydrant 110(shown in FIG. 1 ) when the nozzle cap 150 is mounted on the nozzle 140a (shown in FIG. 1 ). Vibration patterns within the fluid system canindicate the presence of leaks within the fluid system. The vibrationsensor 380 can produce voltage readings when the vibration sensor 380experiences vibrations. These voltage readings can be processed by thePCB 362 to determine whether leaks are present, and a signal can betransmitted outwards from the nozzle cap 150 by the antenna(s) 316 toconvey whether leaks have been identified within the fluid system.

FIG. 3B is a detail cross-sectional view of the cavity gasket 314compressed between the outer housing 240 and the cap cover 280 to form awatertight seal therebetween. As shown, in the present aspect, thecavity gasket 314 can be compressed within a channel 315 formed at thefirst body end 212. As described above, the cavity gasket 314 canprevent moisture and other undesirable elements from entering the cavity310.

Referring to FIG. 4 , according to example aspects, the vibration sensor380 can be a piezoelectric vibration sensor. Piezoelectric vibrationsensors are described in greater detail in U.S. patent application Ser.No. 16/121,136, filed Sep. 4, 2018 and U.S. Pat. No. 9,528,903, issuedDec. 27, 2016, which are hereby incorporated by reference in theirentirety. The vibration sensor 380 can comprise a base 400, at least onepiezoelectric crystal (not shown), and a plurality of calibration masses402. The calibration masses 402 can be distributed circumferentiallyaround the base 400. In the present aspect, the calibration masses 402can be integrally formed with the base 400; however in other aspects,the calibration masses 402 can be separate components which can beattached to the base 400, such as with a glue, adhesive, mastic, epoxy,or another method such as welding, brazing, soldering, or any otherattachment method for example and without limitation. In the presentaspect, the calibration masses 402 can extend axially outward from eachside of the base 400 with respect to the sensor axis 301. A notch 432can be defined between each pair of adjacent calibration masses 402, andthe calibration masses 402 can vibrate independently from one another.

In the present aspect, a fastener 408 of the vibration sensor 380 canextend through the base 400 and piezoelectric crystals and can define athreaded end 410, and a spacer 404 can be fit over the fastener 408between the base 400 and the threaded end 410. Example aspects of thefastener 408 can be formed from a metal material. In the present aspect,the threaded end 410 can define a first sensor end 412 of the vibrationsensor 380, and a second sensor end 414 can be defined by thecalibration masses 402, opposite from the first sensor end 412. Thesensor axis 301 can extend through the fastener 408 and the vibrationsensor 380 as a whole from the first sensor end 412 to the second sensorend 414.

Referring to FIGS. 4 , according to example aspects, a metal insert 420can be received outside of the cavity 310 within the gap 522 (shown inFIG. 5B) formed between the circumferential wall 312 and the internalwall 524 (shown in FIG. 5B) of the cap body 210. In some aspects, thecap body 210 can be formed from plastic and the metal insert 420 can bemolded into the plastic cap body 210. By molding the metal insert intothe plastic housing, a vapor tight seal can be created around the insertwithout the need for additional sealing techniques. The metal insert 420can define a connector 428 extending through an opening 430 in thecircumferential wall 312. In the present aspect, a threaded hole 429 canbe defined in the connector 428, and the threaded end 410 of thefastener 408 can be configured to engage the threaded hole 429 toattached the vibration sensor 380 to the cap body 210 (shown in FIG. 2).

FIG. 5A illustrates the metal insert 420 removed from the nozzle cap150. As shown, the metal insert 420 can comprise a generally toroidalbody 510, which can define an opening 512 through a center thereof. Theopening 512 can be configured to allow a corresponding one of thesecurity screws 336 to pass therethrough. The metal insert 420 canfurther define a top surface 514 and an opposite bottom surface 516, asshown. The connector 428 can extend from the toroidal body 510 in adirection substantially parallel to the top and bottom surfaces 514,516.The threaded hole 429 can be formed in the connector 428 distal from thetoroidal body 510 and can extend towards the toroidal body 510.

Referring to FIG. 5B, as shown, the metal insert 420 can be receivedwithin the gap 522 between the circumferential wall 312 and the internalwall 524. A contact surface 520 of the metal insert 420 can be exposedand can contact the corresponding metal post 332 (shown in FIG. 3A) ofthe inner housing 230 (shown in FIG. 2 ) when the inner housing 230 isassembled to the outer housing 240. In some aspects, the contact surface520 can be the bottom surface 516. As such, when the inner housing 230is connected to the fire hydrant 110 (shown in FIG. 1 ), there can beindirect metal-to-metal contact between the vibration sensor 380 and thefire hydrant 110. For example, in the present aspect, the metal fastener408 of the vibration sensor 380 can be in contact with the metal insert420, the metal insert 420 can be in contact with the corresponding metalpost 332 of the metal inner housing 240, and the metal inner housing 240can be in contact with the metal nozzle 140 a of the metal fire hydrant110. Moreover, the metal fire hydrant 110 can be connected to the metalstand pipe 198 of the fluid system (e.g., a water pipeline), and assuch, there can be an indirect line of metal-to-metal contact betweenthe vibration sensor 380 and the fluid system. As such, vibrations inthe fluid system can be transmitted from the fluid system to thevibration sensor 380 through the metal along the line of metal-to-metalcontact. With the vibration sensor 380 attached to the cap body 210, andthe nozzle cap 150 (shown in FIG. 1 ) attached to the nozzle 140 a(shown in FIG. 1 ), the vibration sensor 380 can detect vibrations fromthe fluid system (not shown) and convert the vibrations to a voltagesignal. When the vibration sensor 380 is exposed to vibrations, thecalibration masses 402 can oscillate axially relative to the base 400which can produce internal stresses within the piezoelectric crystal.Stresses within the piezoelectric crystal can produce a voltage signalwhich can then be interpreted by the PCB 362 (shown in FIG. 3A) todetermine if leaks are present within the fluid system.

FIG. 5C illustrates a cross-sectional view of the metal insert 420engaged with the vibration sensor 380. As shown, in the present aspect,a plurality of ribs 540 can extend across the gap 522 between thecircumferential wall 312 and the internal wall 524 for improved rigidityof the outer housing 240 (shown in FIG. 2 ). A pair of curved insertribs 542 can be formed proximate the metal insert 420, as shown, suchthat the metal insert 420 can be surrounded by and molded with thecurved insert ribs 542, the internal wall 524, and the circumferentialwall 312.

As illustrated in FIG. 6 , some aspects of the cap body 210 (shown inFIG. 2 ) can further define a housing lid 610 configured to engage theouter housing 240 at the first body end 212 of the cap body 210. Exampleaspects of the housing lid 610 can be formed from a plastic material;however, other aspects of the housing lid 610 can be formed from anyother suitable material known in the art. The housing lid 610 can beconfigured to cover the cavity 310, such that the cavity 310 is entirelyenclosed by the outer housing 240 and the housing lid 610. Exampleaspects of the cap body 210 can define a tongue and groove joint 620,wherein a tongue 622 of the joint 620 can be formed on the housing lid610, and a groove 624 of the joint 620 can be formed in the outerhousing 240 at the first body end 212. In other aspects, the tongue 622can be located on the outer housing 240 and the groove 624 can be formedin housing lid 610. The groove 624 can be configured to receive thetongue 622 therein. According to example aspects, the tongue 622 and thegroove 624 of the tongue and groove joint 620 can be ultrasonicallywelded together to form a vapor and watertight seal between the housinglid 610 and the outer housing 240. Ultrasonic welding comprises applyinghigh-frequency ultrasonic acoustic vibrations to two materials (e.g.,the outer housing 240 and the housing lid 610) as they are held togetherunder pressure in order to bond the two materials together. As such, thecavity 310 enclosed by the housing lid 610 and outer housing 240 can beprotected from moisture, along with the sensitive electrical componentsreceived therein, such as the battery pack 360, the PCB 362 (shown inFIG. 3A), the vibration sensor 380 (shown in FIG. 6 , and the antenna(s)316 (shown in FIG. 3A). The watertight seal provided by the ultrasonicwelding can eliminate the need to protect the electronic componentsthrough potting the electronic components within the cavity 310. Inother aspects, the housing lid 610 and outer housing 240 can be joinedtogether by any other suitable fastening means including, for example,traditional welding such as stick welding, mechanical fasteners, or thelike. Furthermore, the outer housing 240 and the housing lid 610 candefine a singular outer module, which can be easily removed from thenozzle cap 150 and replaced with a new outer module, as described above.

As shown, example aspects of the housing lid 610 can also comprise lidfastener holes 614 configured to align with the corresponding fastenerholes 334,344,384 (shown in FIG. 3A) of the inner housing 230 (shown inFIG. 2 ), the outer housing 240, and the cap cover 280 (shown in FIG. 2), respectively. In example aspects, the outer housing 240 can define alocating pin 642 extending from the first body end 212, as shown. Thelocating pin 642 can be configured to engage a recess (not shown) in thehousing lid 610 to aid in properly aligning the corresponding sets oflid and outer fastener holes 614,344 (outer fastener holes 344 shown inFIG. 3A). In some aspects, the recess can be formed has a through-hole,such that the locating pin 642 can extend through a top surface 612 ofthe housing lid 610. The locating pin 642 can then further engage arecess (not shown) formed in the cap cover 280 (shown in FIG. 2 ) to aidin aligning the cap fastener holes 384 (shown in FIG. 3A) formed in thecap cover 280 with the lid and outer fastener holes 614,344 of thehousing lid 610 and the outer housing 240, respectively.

FIG. 7A illustrates a cross-sectional view of the outer housing 240 andthe housing lid 610, taken along line 7-7 in FIG. 6 , with the tongue622 of the tongue and groove joint 620 received within the groove 624 ofthe joint 620. Once received therein, the tongue and groove joint 620can be ultrasonically welded to seal the housing lid 610 with the outerhousing 240. FIG. 7B illustrates a cross-sectional view of the outerhousing 240 and the housing lid 610, taken along line 7-7 in FIG. 6 ,showing the ultra-sonically welded tongue and groove joint 620.

FIG. 8 illustrates an exploded view of the nozzle cap 150, according toanother aspect of the present disclosure. As shown, the nozzle cap 150can comprise the inner housing 230 and the cap cover 280. In the presentaspect, the nozzle cap 150 can further comprise the mechanical spacer810 in place of the outer housing 240 (shown in FIG. 2 ). The spacer 810can replace the outer housing 240 in aspects of the nozzle cap 150 thatmay not require the leak detection, processing, and communicationcapabilities described above. According to example aspects, the spacer810 can be similar to or the same in size and shape to the outer housing240. As shown, the spacer 810 can define spacer fastener holes 814 thatcan be aligned with the inner and cap fastener holes 334,384 of theinner housing 230 and the cap cover 280, respectively, and through whichthe security screws 336 can be received to couple the inner housing 230,spacer 810, and cap cover 280 together. In some aspects, the spacer 810can define a hollow interior (not shown), while in other aspects, thespacer 810 can be solid. The spacer 810 can be formed from any suitablematerial known in the art, including, for example, plastic, metal, orthe like.

The mechanical spacer 810 can be removed from the modular nozzle cap 150and replaced as desired. In instances where it may be desired to obtainthe leak detection, processing, and communication capabilities of theouter housing 240 (shown in FIG. 2 ), the spacer 810 can be easilyremoved from the nozzle cap 150 and can be replaced with the outerhousing 240. For example, the security screws 336 can be loosened orremoved, such that the spacer 810 can be separated from the nozzle cap150. The outer housing 240 can be aligned between the inner housing 230and the cap cover 280, and the security screws 226 can be replaced andre-tightened to secure the outer housing 240 to the nozzle cap 150.Furthermore, as described above, in instances where it may be requiredto replace or repair the outer housing 240, the outer housing 240 can beremoved in the same manner as the spacer 810, and a new or repairedouter housing 240 can be assembled to the nozzle cap 150.

FIG. 9 illustrates an exploded view of the nozzle cap 150 and the nozzle140 a of the fire hydrant 110 (shown in FIG. 1 ), according to oneaspect of the present disclosure, and FIG. 10 illustrates a crosssectional view of the nozzle cap 150 connected to the nozzle 140 a,taken along line 10-10 in FIG. 9 . As described above with reference toFIG. 2 , the inner housing 230 can define the bore 216 extending fromthe second body end 214 to the inner wall 220. The bore 216 can definethe cap axis 201, as shown. In some aspects, as shown, the bore 216 maynot be threaded. In the present aspect, for example, the bore 216 can beun-threaded and the nozzle cap 150 can further define a threaded flange910 extending from the inner wall 220 towards the second body end 214.The threaded flange 910 can define external threading 912 on an outersurface 914 thereof, as shown. The threaded flange 910 can be configuredto engage internal threading 940 formed on the nozzle 140 a. As shown,in the present aspect, the internal threading 940 of the nozzle 140 acan define internal rope threading for attachment of the nozzle cap 150to the nozzle 140 a. Furthermore, in the present aspect, the nozzle 140a can be a Storz nozzle 900. The Storz nozzle 900 can define anon-threaded connection 1002 (shown in FIG. 10 ) for attachment with aStorz pumper hose (not shown). The Storz pumper hose can be attachedwith the non-threaded connection 1002 by a fast and easy quarter-turnaction. The threaded flange 910 can be screwed onto the nozzle 140 a byrotating the nozzle cap 150 about the cap axis 201. The gasket 222 canbe configured to form a seal with the nozzle 140 a when the nozzle cap150 is screwed onto the nozzle 140 a in the sealed position. Note, thenozzle cap 150 illustrated in FIGS. 9-10 is not a modular system;however, the various aspects of the modular nozzle cap 150 describedabove can be used in conjunction with the Storz nozzle 900 of thepresent aspect.

FIG. 11 illustrates an exploded view of the nozzle cap 150 and thenozzle 140 a (for example, the Storz nozzle 900) according to anotheraspect of the present disclosure, and FIG. 12 illustrates across-sectional view of the nozzle cap 150 connected to the nozzle 140a, taken along like 12-12 in FIG. 11 . In the present aspect, like theaspect of FIG. 2 , the inner housing 230 can define the threaded bore216, and the threaded bore 216 can define the internal threading 218.The nozzle 140 a can define external threading 1140 configured to matewith the internal threading 218 of the inner housing 230. The threadedbore 216 can be screwed onto the nozzle 140 a to mount the nozzle cap150 on the nozzle 140 a, and the gasket 222 can create a seal with thenozzle 140 a when the nozzle cap 150 is screwed onto the nozzle 140 a inthe sealed position. Note, the nozzle cap 150 illustrated in FIGS. 11-12is not a modular system; however, the various aspects of the modularnozzle cap 150 described above can be used in conjunction with the Storznozzle 900 of the present aspect.

Referring to the exploded view of FIG. 13 , in some aspects, the outerhousing 240 can comprise a vent 1310, such as, for example, a Gore®vent. As shown, the vent 1310 can comprise a membrane 1320 mounted tothe inner wall 220 of the cap body 210 (shown in FIG. 2 ). For example,the membrane 1320 can be mounted to ribs 1322 formed on the inner wall220. In the present aspect, the ribs can be substantially circular inshape. (Note, in the exploded view of FIG. 13 , the membrane 1320 isillustrated elevated above the circular ribs 1322.) In the presentaspect, the membrane 1320 can be positioned beneath the PCB 362,relative to the orientation shown. A small opening 1324 or openings canbe formed in the inner wall 220 beneath the membrane 1320. The membrane1320 can allow airflow therethrough to allow for pressure equalizationwithin the enclosed cavity 310 in instances where the cavity 310 issubjected to harmful pressure changes. Changes in pressure can placestresses on various components of the nozzle cap 150 (shown in FIG. 1 ),and the capability to equalize the pressure within the cavity 310 canreduce stresses and increase the lifespan of the nozzle cap 150. Exampleaspects of the membrane 1320 can also be waterproof and can preventmoisture and other undesirable elements, such as dirt, from entering thecavity 310.

FIG. 14 illustrates a detail cross-sectional view of the nozzle cap 150(shown in FIG. 1 ), taken along line 14-14 in FIG. 3 . As shown, one ofthe security screws 336 can extend through the corresponding fastenerholes 334,344,384 of the inner housing 230, the outer housing 240, andthe cap cover 280, respectively. The security screw 336 can also extendthrough the opening 512 of the metal insert 420. In some aspects, to aidin preventing or reducing deformation of the plastic outer housing 240,the nozzle cap 150 can comprise a disc spring 1410 positioned betweenthe fastener hole 384 of the cap cover 280 and a head 1436 of thesecurity screw 336, as shown. The disc spring 1410 can be, for example,a coned-disc spring (i.e., a Belleville washer), or any other suitabletype of disc spring known in the art, and can be configured to deflectunder a load. According to example aspects, the disc spring 1410 candefine a disc opening 1412 through which the security screw 336 canextend. Each of the other security screws 336 of the nozzle cap 150 canalso extend through a disc spring 1410 positioned between thecorresponding head 1436 thereof and the corresponding fastener hole 384.

To further aid in reducing deformation of the outer housing 240, exampleaspects of the nozzle cap 150 can also comprise a compression limiter1420 positioned between the cap cover 280 and the metal insert 420, asshown. Example aspects of the compression limiter 1420 can define acompression limiter opening 1422 through which the security screw 336can extend. The compression limiter 1420 can be formed from a metalmaterial, such as, for example, steel, aluminum, brass or any othersuitable material known in the art, and can be configured to improve thestructural integrity of the plastic joint at the corresponding fastenerhole 344 in the outer housing 240. Each of the other security screws 336can also extend through a compression limiter 1420. However, in someaspects, because the other security screws 336 do not extend through themetal insert 420, the corresponding compression limiters 1420 can extendfully between the cap cover 280 and the corresponding post 332 of theinner housing 230.

One should note that conditional language, such as, among others, “can,”“could,” “might,” or “may,” unless specifically stated otherwise, orotherwise understood within the context as used, is generally intendedto convey that certain embodiments include, while other embodiments donot include, certain features, elements and/or steps. Thus, suchconditional language is not generally intended to imply that features,elements and/or steps are in any way required for one or more particularembodiments or that one or more particular embodiments necessarilyinclude logic for deciding, with or without user input or prompting,whether these features, elements and/or steps are included or are to beperformed in any particular embodiment.

It should be emphasized that the above-described embodiments are merelypossible examples of implementations, merely set forth for a clearunderstanding of the principles of the present disclosure. Any processdescriptions or blocks in flow diagrams should be understood asrepresenting modules, segments, or portions of code which include one ormore executable instructions for implementing specific logical functionsor steps in the process, and alternate implementations are included inwhich functions may not be included or executed at all, may be executedout of order from that shown or discussed, including substantiallyconcurrently or in reverse order, depending on the functionalityinvolved, as would be understood by those reasonably skilled in the artof the present disclosure. Many variations and modifications may be madeto the above-described embodiment(s) without departing substantiallyfrom the spirit and principles of the present disclosure. Further, thescope of the present disclosure is intended to cover any and allcombinations and sub-combinations of all elements, features, and aspectsdiscussed above. All such modifications and variations are intended tobe included herein within the scope of the present disclosure, and allpossible claims to individual aspects or combinations of elements orsteps are intended to be supported by the present disclosure.

That which is claimed is:
 1. A nozzle cap for a fire hydrant comprising:a cap cover comprising a metal material; and a cap body defining a capaxis, the cap body comprising: an inner housing comprising a metalmaterial; and an outer housing comprising a non-metal material, theouter housing disposed axially between the inner housing and the capcover, the outer housing comprising a substantially circumferentialwall, the substantially circumferential wall defining a cavity betweenthe inner housing and the cap cover, wherein a first end of thesubstantially circumferential wall engages the inner housing.
 2. Thenozzle cap of claim 1, further comprising an antenna installed on thenon-metal material of the outer housing.
 3. The nozzle cap of claim 2,wherein the non-metal material is a non-ferrous material configured toprevent the outer housing from interfering with a signaling ability ofthe antenna.
 4. The nozzle cap of claim 1, further comprising a housinglid ultrasonically welded to the outer housing and configured to enclosethe cavity.
 5. The nozzle cap of claim 4, further comprising a tongueand groove joint, the tongue and groove joint comprising a tongue formedon one of the housing lid and the outer housing and a groove formed inthe other of the housing lid and the outer housing.
 6. The nozzle cap ofclaim 4, wherein; the outer housing defines an outer fastener hole; thehousing lid defines a lid fastener hole; and a fastener extends throughthe outer fastener hole and the lid fastener hole.
 7. The nozzle cap ofclaim 6, wherein the outer housing further comprises a locating pinconfigured to engage a lid recess formed in the housing lid to align theouter fastener hole of the outer housing with the lid fastener hole ofthe housing lid.
 8. The nozzle cap of claim 7, wherein: the cap coverdefines a cover recess and a cap fastener hole; and the locating pinextends through the lid recess of the housing lid and engages the coverrecess of the cap cover to align the cap fastener hole with the outerfastener hole and the lid fastener hole.
 9. The nozzle cap of claim 1,wherein: the inner housing further comprises a membrane; the membrane isconfigured to allow air to pass therethrough and to prohibit liquid frompassing therethrough; and the membrane is mounted to an inner wall ofthe cap body.
 10. The nozzle cap of claim 1, further comprising at leastone of a disc spring and a compression limiter.
 11. A nozzle cap for afire hydrant comprising: a cap cover comprising a metal material; a capbody defining a cap axis, the cap body comprising: an inner housingcomprising a metal material; and an outer housing comprising a non-metalmaterial, the outer housing disposed axially between the inner housingand the cap cover, the outer housing comprising a substantiallycircumferential wall, the substantially circumferential wall defining asubstantially cylindrical surface; and an antenna assembly comprising atleast an antenna and an adhesive, the antenna assembly comprising a freefirst side end, a free second side end, a free upper end, and a freelower end, the adhesive adhering the antenna directly to a first portionof the substantially cylindrical surface, wherein a second portion ofthe substantially cylindrical surface is uncovered by the antennaassembly, wherein an area of the second portion is greater than an areaof the first portion.
 12. The nozzle cap of claim 11, wherein theantenna assembly is formed as a patch.
 13. The nozzle cap of claim 12,wherein the patch is substantially rectangular in shape.
 14. The nozzlecap of claim 11, wherein: the inner housing comprises a threaded boreconfigured to couple the nozzle cap to a nozzle of the fire hydrant; andthe threaded bore extends into the inner housing and is configured toengage threading of the nozzle of the fire hydrant.
 15. The nozzle capof claim 11, wherein: the cap cover defines a cap fastener hole and theouter housing defines an outer fastener hole; the nozzle cap furthercomprises a fastener extending through the cap fastener hole andengaging the outer fastener hole to secure the cap cover to the outerhousing; fastener further engages an inner fastener hole of the innerhousing to secure the cap cover and the outer housing to the innerhousing; and the outer housing is retained between the cap cover and theinner housing by the fastener.
 16. The nozzle cap of claim 15, whereinthe inner fastener hole is a threaded hole, and wherein the fastener isa security screw defining a head and a threaded tail end, the threadedtail end extending through the cap cover and the outer housing andengaging the threaded hole of the inner housing.
 17. The nozzle cap ofclaim 11, further comprising a sensor configured to detect leaks in afluid system connected to the fire hydrant, wherein the antenna is inelectrical communication with the sensor, the antenna configured totransmit a signal conveying whether a leak has been detected by thesensor.
 18. The nozzle cap of claim 17, wherein: the outer housingfurther defines a cavity; the nozzle cap further comprises a processorreceived in the cavity; and the processor is configured to receive andprocess readings from the sensor and to communicate information relatedto the readings to the antenna.
 19. The nozzle cap of claim 18, whereinthe sensor is a vibration sensor configured to detect vibrations in thefire hydrant.